Ballistic panel apparatus

ABSTRACT

A ballistic panel composed of multiple layers. An outer layer is preferably metal. An inner layer is provided that can serve as decorative, if desired. Adhered to the outer layer is a layer of ballistic material, preferably KEVLAR or other synthetic ballistic fiber. Foamed in place is a layer of foam, preferably urethane. Also, featured is a plurality of cam locks with each cam lock having a male and a corresponding female part such that the adjacent panels can be easily and quickly locked together to form a safe enclosure.

This application claims benefit of U.S. Provisional Application Ser. No. 61/575,203 filed on Aug. 16, 2011, pursuant to 35 USC §119(e).

FIELD OF THE INVENTION

This invention relates to armor systems for protection against various safety issues such as might be experienced with a typical tornado, hurricane or even against ballistic projectiles in terrorist or criminal situations, in particular, ballistic panels that can be easily and quickly locked together to form buildings, rooms or other enclosures such as a “safe” room.

BACKGROUND OF THE INVENTION

Given current economic conditions and the level of terrorist activities at home and aboard as well as the current cycle of more frequent severe weather, the need for rapidly deployable, lightweight, cost effective protection has reached an all time high. While conventional armament such as steel plates provide sufficient protection, weight, cost and difficulty in installation, this choice of conventional armament impractical except in military situations.

U.S. Pat. No. 7,921,759, issued to Warren on Apr, 12, 2011, is directed towards providing a ballistic panel that is useful for protecting military vehicles in battle conditions for protection against enemy fire. This patent teaches the use of a panel comprising multiple layers having a grinding layer including ceramic spheres. Not only is this construction very expensive to achieve, there is no provision for easily attaching these panels to one another.

There is not found in the prior art, a ballistic panel that is inexpensive to construct, quickly and easily attached together to form an enclosure, and light enough to use in residential environments.

SUMMARY OF THE INVENTION

It is an aspect of the invention to provide a ballistic panel that is fabricated from polyurethane foam that provides protection without the weight of prior art armaments.

It is still another aspect of the invention to provide a ballistic panel that uses ballistic resin/fiber material such as KEVLAR to provide protection.

Another aspect of the invention is to provide a ballistic panel that has cam locks that enable one panel to be quickly and easily attached to an adjacent panel.

It is another aspect of the invention to provide a ballistic panel that uses lightweight outer skins to provide the structure of the panel.

A further aspect of the invention is to provide a ballistic panel that also has a high insulation R-value such that the panel can be used for refrigerated storage or in high heat situations.

Finally, it is an aspect of the invention to provide a ballistic panel that can be locked together to provide an enclosure such as a room or even a building.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a detailed schematic showing the panel in accordance with the invention.

FIG. 2 is schematic showing the panels that can be attached together to provide an enclosure.

FIG. 3 is a typical enclosure showing multiple panels attached together.

DETAILED DESCRIPTION OF THE INVENTION

As shown in FIG. 1, a typical multi-layer ballistic panel is constructed in accordance with invention 10. Outer layer 12 is preferably made of metal, preferably light gauge steel approximately 0.015 inches thick. Thicker steel up to 0.125 inches could also be used. Even aluminum might be a suitable substitute depending on the particular installation that panel 10 is being used Inner layer 14 or outer layer 12 could use decorative panels for the outer and inner skins such as FORMICA type of laminates. Also, flame retardant plastic sheeting could be substituted for uses where sparks or open flames are likely to be encountered. For finished enclosures, gypsum board or decorative plywood or other panel could also be suitable substitutes.

The core of foam 16 of the ballistic panel is made from polyurethane foam. Polystyrene foam could also be used. Foam layer 16 is preferably poured in place with high-pressure foam machines. Thicknesses could range from 1 inch to up to 6 inches thick. Foam layer 16 provides the structure of panel 10 and acts as a binder to hold ballistic rated material layer 18 and cam locks 19 in place.

As noted, invention panel 10 is especially useful for insulation purposes. Each inch of foam thickness provides an R-value of 8. Thus, panel 10 is ideal for use in refrigerated storage situations. It is also ideally suited for use in modular buildings and enclosures where extreme hot or cold climate conditions are expected.

Ballistic rated material layer 18 is preferably made from KEVLAR, E.I. Dupont's trademarked identification for its para-aramid synthetic fiber. However, other ballistic materials such Ballistic Ceramics, DYNEMA, a high strength polyethylene fiber, tempered steel or ballistic fiberglass phenolics, PBO fibers as well as other ballistic materials could be used as well.

Ballistic layer 18 is adhered to the outer skin by high strength construction adhesive and is held permanently in place when the foam is injected into the panel during the manufacturing process. The thickness of ballistic layer 18 will be determined by the threat level to panel 10 that is expected.

As shown in FIG. 2, cam locks 19 are used to quickly and easily fasten the panels together to form an enclosure. Cam locks 19 are foamed in place along each panel edge. Each lock consists of two parts, one male 20 and one female 22. Male half 20 provides the cam and the locking arm. Female half 22 holds a fixed pin. When the panels are placed adjacent to one another, male lock cam 20 is turned and the locking arm reaches out and engages the pin in female half 22. As the cam is turned, the locking arm is drawn toward female half 22 such that the two panels are down snugly together forming a tight seam 24.

As shown in FIG. 3, an enclosure comprising floor panels 30, roof panels 26 and wall panels 28 all fasten together with these cam locks 19.

Although the present invention has been described with reference to certain preferred embodiments thereof, other versions are readily apparent to those of ordinary skill in the preferred embodiments contained herein. 

What is claimed is:
 1. A multi-layer ballistic panel comprising: an outer layer; wherein said outer layer is a sheathing ranging from 0.015 to 0.125 inches thick and, wherein said outer layer is made from a material selected from the group consisting of steel, aluminum, laminates, plastics, plywood, or gypsum board; and an inner layer, wherein said inner layer is made from a material selected from the same group of materials as recited for the outer layer but not necessarily the same material selected for said outer layer; and a ballistic layer adhered to said outer layer, wherein said ballistic is made from a material selected from the group consisting of a para-aramid synthetic fiber, ceramics, high strength polyethylene fiber, PBO fiber, fiberglass phenolic as well as other well known synthetic and natural ballistic materials, wherein said ballistic layer is adhered to said outer layer; and a foam core that is injected in place between said inner layer and said outer layer with said ballistic layer adhered thereto to provide said multi-layer ballistic panel.
 2. The multi-layer ballistic panel of claim 1 wherein said foam layer is made of a polyurethane foam.
 3. The multi-layer ballistic panel of claim 1 wherein said foam layer is made of a polystyrene foam.
 4. The multi-layer ballistic panel of claim 1 further comprising at least one two-part cam lock.
 5. The multi-layer ballistic panel of claim 4 further comprising at least one part of a two-part cam lock that is foamed in place along at least one edge of said panel.
 6. The multi-layer ballistic panel of claim 5 wherein each said cam lock has a male part and a corresponding female part in a corresponding adjacent panel so that the two adjacent panels can be locked together.
 7. The multi-layer ballistic panel of claim 6 wherein said male part of said cam lock comprises a cam and a locking arm and where said female part comprises a locking pin, such that when said male part of said cam lock is adjacent to the female part of an adjacent cam lock, when two panels are placed adjacent to one another, the male lock cam is turned and the locking arm reaches out and engages the pin in the female half such that as the cam is turned, the locking arm is drawn toward the female half such that the two panels are down snugly together forming a tight seam.
 8. The multi-layer ballistic panel of claim 1 wherein said foam core ranges from approximately 1 inch thick to 6 inches thick.
 9. The multi-layer ballistic panel of claim 1 wherein the thickness of said ballistic layer is determined in accordance with the expected threat that said panel must withstand.
 10. The multi-layer ballistic panel of claim 1 wherein a plurality of said panels may be locked together to form an enclosed structure.
 11. The multi-layer ballistic panel of claim 10 wherein said enclosed structure is a refrigerated storage unit.
 12. The multi-layer ballistic panel of claim 10 wherein said enclosed structure is a used in an environment wherein high ambient temperatures can be expected.
 13. The multi-layer ballistic panel of claim 10 wherein said enclosed structure is a safe room that provides protection from external threats to the occupants of said enclosed structure.
 14. The multi-layer ballistic panel of claim 10 wherein said enclosed structure is a located in a combat situation.
 15. The multi-layer ballistic panel of claim 1 wherein a plurality of panels can be locked together to form a structure that is useful in a combat situation where projectiles can be expected to strike said structure. 